Room constructing

ABSTRACT

A pre-manufactured building structure including at least one building module for providing a temporary or permanent dwelling space. The module includes wall, floor and ceiling members formed from precast concrete and configured for detachable engagement to one another to form an enclosed space. Adjacent wall, floor and ceiling members are spaced apart from each other by a predetermined distance. A compliant pad spans this distance to couple adjacent members and accommodate relative movement between the members during transport and after installation of the structure.

TECHNICAL FIELD

This invention relates to pre-manufactured concrete building structures,and more particularly, to building structures which can be attached toand removed from existing structures for repeated use.

BACKGROUND

For background, reference is made to U.S. Pat. Nos. 4,171,596,4,275,533, 4,573,292, 4,745,719, 5,265,384, 5,727,353, 5,845,441, and6,330,771.

SUMMARY

There is a need to provide portable structures to function as schoolclassrooms, office spaces, and/or apartments in a economical andexpeditious way. Readily adaptable and configurable building facilitiesare required to meet the rapidly changing requirements for facilitiessuch as school classrooms. Structures according to the invention areformed from pre-manufactured modules which can be joined in manyconfigurations for serving temporary or long term building needs.

Structures according to the invention can be readily attached to anexisting building or serve as a standalone structure. In addition, thestructure can be used for a number of years after being delivered to thesite. If and when the demographics again change and the additional spaceafforded by the structure is no longer needed, the structure can bedetached and moved to a new site for expansion of a new school facility.

Specifically in school applications, the total lead time from planningthrough commissioning, to building operation can take more than sixyears. With typical school expansion projects, an architectural firmwill spend substantial efforts to develop and plan structures fittingthe classrooms to the particular needs of the school. However, whenspecifying building modules according to the invention, the timerequired to plan and build the additional space is minimized. Thenecessity for numerous site specific shop drawings is also reducedbecause the specifications of the structure according to the inventionare predefined. Through application of structures according to theinvention, the delivery time and the costs of construction can begreatly reduced. Architects, engineers and school officials knowbuilding dimensions, specifications and costs in advance. Therefore,site specific planning and variability is vastly reduced. The totalconstruction time is reduced because precasting of the building modulescan be done concurrent with preparation of the existing school facilityand adjacent construction site.

In one aspect according to the invention, a building structure includesat least one building module for providing a temporary or permanentdwelling space, the module including wall, floor and ceiling membersformed from reinforced precast concrete. The members are detachablycoupled to one another to form an enclosed space, with adjacent membersbeing spaced apart from each other a predetermined distance. A compliantpad spans this distance and couples adjacent members to accommodaterelative movement between the members during transport and once thestructure is located on the site.

In one embodiment, the compliant pad is a synthetic rubber. In anotherembodiment, the structure includes a concrete form attached to theceiling to accommodate fixtures, electrical conduit or suspendingceiling materials. The concrete form can include a channeled layer, suchas a composite floor deck ceiling system, including EPICORE® (EpicMetals Corporation, Rankin, Pa.), for example. In another embodiment,the members of the structure are further adapted to detachably engage asecond additional building module, comparable to the first module, toform a single larger structure. The modules can be arranged verticallyto form a multiple-story building or connected along a horizontalorientation to form a larger single-story structure.

The structure can also include a conduit extending through the membersfor accommodating building utilities including at least one of plumbing,electrical, heating, ventilating, and air conditioning. The structurecan also be adapted for attachment to an preexisting structure. Thestructure can also include any of number of exterior facade surfaces,such as brick, stone, stucco, or any combination thereof.

According to another aspect, of the invention, a portablepre-manufactured building includes a generally parallelepipal structurefor releasable attachment to a pre-existing structure having verticalwalls, a horizontal floor, and a horizontal ceiling. The walls andceilings are formed from cast concrete including reinforcing steel rebarand include a connecting layer disposed between the top of the walls andthe ceilings. Wall members can also include at least one conduit foruninterrupted passage of utilities.

In a various embodiments, the connecting substrate is a syntheticrubber, such as neoprene, for example. A channeled layer, such asEPICORE® or equivalent, can be attached to the floor and ceilingmembers. The members of the structure can be further adapted todetachably engage a second additional structure, comparable to the firststructure, to form a single larger structure. The structure can alsoinclude a conduit extending through the wall members for accommodatingbuilding utilities, including, for example, at least one of plumbing,electrical, heating, ventilating, and air conditioning.

The details of one or more embodiments of the invention are set forth inthe accompanying drawings and the description below. Other features,objects, and advantages will be apparent from the detailed description,which refers to the following drawings, in which:

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a pre-manufactured concrete buildingmodule according to the invention;

FIG. 2 is a perspective view of two of the building modules shown inFIG. 1, arranged in a vertical configuration;

FIG. 3 is a floor plan view of a pre-manufactured concrete buildingmodule attached to an existing building;

FIG. 4 is a section view of the building module of FIG. 3 through lineA-A;

FIG. 5 is a floor plan view of the structure of FIG. 1;

FIG. 6 is a cross-section elevation view of the typical wall andfoundation construction;

FIG. 7 is a cross-section elevation view of wall, floor, and foundationconstruction;

FIG. 8 is a detail cross-section view of the junction between ceilingand wall members and floor and ceiling members;

FIG. 9 is another detail cross-section view of the junction betweenceiling and wall members and floor and ceiling members;

FIG. 10 is a detail cross-section view of the junction between floor,ceiling, and wall members which depicts the attachment to the buildingfoundation;

FIG. 11 is a detail cross-section view of a junction between adjacentfloor members and a wall member;

FIG. 12 is a detail cross-section view of a window installed in a wallmember; and

FIG. 13 is a detail view of an exterior door and an attached foldingstair.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This invention relates to a system of pre-manufactured concrete modulesthat can serve as a freestanding school classroom, expand a preexistingschool, apartment units, small office of other commercial space.Construction details permit the option of readily adding exteriorfacades such as brick, stucco, stone or lapboard, for example, toarchitecturally blend the new structure with the existing structure.Individual modules can be connected horizontally and/or verticallystacked to form multi-story structures. The room sizes may vary as toneed and desire so that the rooms can be versatile and the only thingthat will be required is that the room sizes can be engineeredeconomically and safely. The modules forming the building structure canbe constructed to withstand hurricanes, rainstorms, windstorms,snowstorms, and if geographic conditions warrant, seismic activity.

For classroom applications, the modules can readily provide additionalstudent capacity when demographic changes require it. The modules can beattached to and integrated with the existing school and not an isolated“portable” style classroom. The modules can be delivered to theconstruction site and furnished with interior features, desks,chalkboards. The modules can be located to form hallways and bathrooms,for example. In commercial applications, the modules can be arranged invarious horizontal and vertical configurations to meet the particularbuilding requirements.

With reference now to the drawings and more particularly to FIG. 1,there is shown a concrete building module 20 according to the invention.The module 20 can be pre-manufactured in a factory to desiredspecification and include all building facilities, such as bathrooms,closets, hallways, interior wall furnishings, and lighting fixtures, forexample, and ready for use after placement and installation at theconstruction site. Alternatively, if practical, the module can be castonsite. The module 20 is a single story building having a generallyrectangular floor plan and is formed from steel reinforced concretefloor member 22, wall members 24 and roof member 26. Other floor plandimensions are contemplated to meet individual building requirements.The floor, wall, and roof member 22, 24, 26 can be formed fromreinforced concrete slab having a thickness of six inches. In oneembodiment, the roof member 26 extends beyond an exterior wall member 24in one direction to form an overhang 28. The concrete roof member 26 canbe coated with a waterproof layer or membrane, such as a thorosealmaterial, for example. The roof member 26 can also be flat or pitchedalong the lateral dimension of the module 20 at a suitable pitch, suchas ¼-inch per foot for improved drainage.

The module 20 can also include preinstalled windows 30 and doors 32.Cutouts 34 in wall members 24 adjacent the roof members 26 form conduitsfor continuous piping 36 from one module 20 to another adjacent module,comparable to module 20, or to a preexisting building. The floor, wall,and roof members 22, 24, 26 are cast individually in appropriately sizedforms and then joined together as described below. The interior surfacesof the wall members 24 can be covered with drywall or painted plywood.Optional facings 38 can be attached to the exterior surfaces of the wallmembers 24, such as brick, stone, stucco, or lapboard for example, toconform the building module 20 to the preexisting building to which itcan be attached.

Referring to FIG. 2, the modules 20 can be stacked to form the two-storystructure 40 as shown. Up to the three modules can be stackedvertically. The modules can also be attached horizontally (not shown),to form a larger, single-story structure. Junctions (discussed below)disposed between adjacent members of the modules 20 connect the firstand second modules together. The structure 40 is supported by concretepilings 42 or concrete footings spaced along the underside of the floormember 22 of the first-story module. Along the mating surfaces betweenthe modules, filler strips 44 consisting of elongate decorative metal orplastic panels, can be attached.

The structure 40 can serve as a standalone classroom, with interiorfacilities including blackboards/whiteboards, clocks, closets andcabinetry and desks, for example. As shown in FIGS. 3 and 4, thestructure 40 can function as an addition to an existing school building.Preferably, the structure 40 is attached to the existing school buildingand integrated into the design of the school. FIG. 3 depicts anaggregation of structures 40 to form a wing 41 extending from anexisting building 43. In this example, the wing 41 includes two sets oftwo structures 40 a, 40 b, 40 c and 40 d, connected by a hallway section45 spanning the adjacent units. The wing 41 is attached to the building43 by vestibules 47 extending therebetween. As shown in FIG. 4, floormember 49 extends from a first structure 40 a to a second structure 40c, 40 d. One end of the member 49 bears on notch unit 51. A roofextension member 53 spans the roof members of structures 40 a and 40 c.In one example, the roof is arcuate and includes a skylight (shown inphantom). Alternatively, the structure 40 is located proximate to theschool for ready accessibility. In the classroom application, thestructure 40 can also be assembled and installed on site to meet theneeds of increased enrollment at a particular school and later, ifenrollment drops, detached and reinstalled for use in a different schooldistrict. The structure 40 can also serve individually or collectively,as apartment units, office space, or commercial retail space.

A representative floor plan shown in FIG. 5, shows exterior dimensionsof about 20 by 30 feet. Although the floor plan shown is rectangular,other dimensions, as dictated by the site, the specifications, and theexisting structure (if an expansion), are contemplated. The floor member22 is formed from one or more slabs of reinforced concrete, similar toroof member 26, with a thickness of six inches. Flat beams 46 extendbeneath the floor member 26 to support the module 20 on pilings and/orfootings 42 (FIG. 2). Interior spaces such as closets 50 are formed withinternal, non-load bearing walls 52, framed with metal or wood studs,having a thickness of six inches.

As shown in FIG. 6, steel rods 52 extend vertically between upper andlower horizontal steel beams 52, 54, respectively, for reinforcing thewall member 24. The module 20 is supported by pilings 42 positionedalong the span of floor member 22 and corresponding to the flat beams 46(FIG. 5). The ceiling height is nominally 9 feet.

Referring now to FIG. 7, the floor, wall, and ceiling members 22, 24, 26are joined together along wall-to-roof member junctions 60,wall-to-single floor member junctions 62, wall-to-two floor memberjunctions 64, a and floor-to-floor junctions 66. The wall and roofmembers in junction 60, the wall and floor members in junction 62, andthe wall and floor members in junction 64 are separated a vertical gapor distance D₁. This distance is filled by a compliant pad 70 disposedbetween the concrete members. The pad 70 can be formed from a commercialavailable synthetic rubber compound, such as neoprene. A sealant 72 isapplied along the peripheral edges of the pad 70 to substantially sealthe connection against infiltration of weather and debris. Adjacentfloor members 22 at junctions 64 and 66 are separated by a horizontalgap of distance D₂ filled with sealant 72 to bridge the gap. Thevertical and horizontal gaps defined by D₁ and D₂, respectively, injunctions 60, 62, 64, and 66, spanned by pad 70 or filled with sealant72, permit relative movement between wall, floor, and roof membersduring transport and after installed at the site to accommodate buildingsettling, while also mitigated cracking and other damage to concretemembers 22, 24, and 26 of the structure 40 (FIG. 2).

FIGS. 8, 9, and 10 show the junctions 60, 62, 64 and 66 in greaterdetail. Generally the detailed view of a typical joint, depicted in FIG.11, shows the ends of adjacent floor members 22 positioned proximate oneanother and separated by a horizontal gap of distance D₂ filled withsealant 72. A compliant pad 70 is interposed between the wall member 24and the two floor members 22, spanning the vertical distance D₁. A layerof sealant 72 also extends along the periphery of the compliant pad 70to substantially seal the connection against infiltration of weather anddebris. Reinforcing steel rebar 52 extends vertically through the wallmembers 24 to strengthen the wall members in tension, as is commonlyknown in the art. For those areas of steel rebar 52 which are exposed, alayer of anticorrosive paint can be applied to resist oxidation of therebar. A channeled layer 78 is attached to the lower surface of thefloor members 22. The channeled layer 78 can include metal decking forsupporting ceiling fixtures, containing insulation or concealing pipesand ventilation components, for example. A second complaint pad 80,spanning a vertical distance D₃, is disposed between the channeled layer78 and the flat beam 24.

The compliant pads 70, 80 can be made from commercially availablesynthetic rubbers, such as neoprene, for example. Collectively, pad 70,extending along the distance D₁, second pad 80 extending between thelayer 78 and the flat beam 24, and horizontal gap of distance D₂, filledwith sealant 72, prevent direct contact between the wall and floormembers 22, 24, which accommodates relative moment therebetween fortransport and settling while still maintaining sufficient dimensionalstability and rigidity of the structure. Referring to FIG. 10, the wallsection 24 is supported by piling 42. The flat metal beam 46 is rigidlyconnected to the concrete pile 42 (or footing) beneath it, by a steelstrap 82, for example.

FIG. 12 shows a typical window section. A window 100, bounded by awindow frame 102, is installed within corresponding open of wall member24, according to standard, accepted installation techniques. A concreteteat 104 or 1-inch pressure-treated wood beam is positioned along thetop of the window 100. About all sides, the window frame 102 is securedin place with screws fastened to lead shields 106 which are attached tothe opening in the wall member 24. Pressure treated wood trim 108 andwindow sealant 110 are attached along the outside perimeter of theopening in the wall section 24 along the window 100. The decorativefacade 38, attached to the exterior surface of the wall member 34 canextend proximate the lowest edge of the window 100 to form a window sill112. The sill 112 can be pitched downward away from the window 100 tofacilitate drainage of rain water. An interior wall 114, attached to theinside surface of the wall member 24, can be ⅝-inch drywall or paintedplywood 112, for example.

FIG. 13 shows a detailed view of the lower edge of door 32. The door canbe solid wood, fiber glass-composite heavy-gauge, galvanized steel overa core of rigid foam, for example. If the doors 32 open to the outside,an exterior door sill 118 extends from the floor member 22 to engage thelower edge of the door 32 and provide a tight seal. Folding stairs 120can be attached to the inside of the door 32 for emergency egress fromthe structure 40. The stairs 120 can include a rope 122, attached to thestairs, for extending the stair 120 away from the door 32.

A number of embodiments have been described herein. Other embodimentsare within the scope of the following claims.

1. A premanufactured building structure, the structure comprising: abuilding module for providing a temporary or permanent dwelling space,said module comprising wall, floor and ceiling members formed fromprecast concrete and detachably coupled to one another to form anenclosed space, the adjacent members being spaced apart from each othera predetermined distance; and a compliant pad spanning the distance andcoupling adjacent members to accommodate relative movement between themembers.
 2. The structure of claim 1 wherein the compliant pad is asynthetic rubber.
 3. The structure of claim 1 further comprising achanneled layer attached to the floor and ceiling membersto accommodatefixtures, electrical conduit or suspending ceilings.
 4. The structure ofclaim 3 wherein the channeled layer comprises a composite floor deckceiling system.
 5. The structure of claim 1 wherein the building moduleis further adapted to detachably engage a second building module,comparable to said building module, to form a single larger structure.6. The structure of claim 5 wherein the modules are stacked vertically.7. The structure of claim 5 wherein the structures are connected along ahorizontal orientation.
 8. The structure of claim 1 further comprising aconduit extending through the members for building utilities includingat least one of plumbing, electrical, heating, ventilating, and airconditioning.
 9. The structure of claim 1 adapted for attachment to apreexisting structure.
 10. The structure of claim 1 further comprisingexterior facade surfaces.
 11. The structure of claim 1 wherein themodule serves as a school classroom.
 12. The structure of claim 1wherein the module serves as an apartment unit.
 13. The structure ofclaim 1 wherein the module serves as an office space.
 14. A firstportable pre-manufactured building structure, the structure comprising:a generally parallelipepal first structure for releasable attachment toa pre-existing structure having vertical wall, horizontal floor andhorizontal ceiling members; the walls and ceilings members comprisingcast concrete including reinforcing steel rebar; a connecting layerdisposed between the top of the wall and the ceiling members; the layercomprising neoprene pads and a channeled layer attached thereto; and atleast one conduit for uninterrupted passage of utilities.
 15. Thestructure of claim 14 wherein the connecting layer is a syntheticrubber.
 16. The structure of claim 14 wherein the channeled layercomprises a composite floor deck ceiling system.
 17. The structure ofclaim 14 wherein the exterior surfaces of the first structure arefurther adapted to detachably engage exterior surfaces of a secondadditional structure, comparable to said structure, to form a singlelarger structure.
 18. The structure of claim 17 wherein the first andsecond structures are stacked vertically.
 19. The structure of claim 17wherein the firsthand second structures are connected along a horizontalorientation.
 20. The structure of claim 17 further comprising a conduitextending through the members for building utilities including at leastone of plumbing, electrical, heating, ventilating, and air conditioning.